Engineered stone product and methods of making the same

ABSTRACT

An engineered stone product is made using a material that includes ceramic powder, glass sand, and a binder.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/297,448, filed May 26, 2021, which is a U.S. national phase entry ofInternational Patent Application No. PCT/CN2018/120687, filed on Dec.12, 2018, the content of each is incorporated herein by reference in itsentirety.

FIELD OF THE DISCLOSURE

This disclosure relates to engineered stone products and methods,specifically to ceramic-based engineered stone products and methods.

BACKGROUND

Engineered stone products are used for a variety of purposes includingcountertops, flooring, furniture surfaces, building decorative panels,wall tiles, and the like. Many engineered stone products aremanufactured using quartz sands as their main component, and have gainedconsumer favor because they can be less porous and more durable thancertain naturally occurring stone materials, but can achieve similaraesthetic properties.

However, engineered stone products which use quartz sands as their maincomponent still suffer from several drawbacks. For example, they areproduced having a limited glossy sheen, colors may fade out or bleedfrom the engineered stone, and they are often unsuitable for outdooruse. Further, the performance of engineered stone products which usequartz sands as their main component is often limited by the quality ofthe quartz sands, which are a naturally-occurring material. Accordingly,the quality of quartz sands is variable, and the quantity of quartzsands available is decreasing over time.

Accordingly, improved engineered stone products are needed.

SUMMARY

This summary is provided to introduce various concepts in a simplifiedform that are further described below in the detailed description. Thissummary is not intended to identify required or essential features ofthe claimed subject matter nor is the summary intended to limit thescope of the claimed subject matter.

In one aspect, an engineered stone product is provided including ceramicpowder, glass sand, and a binder.

In another aspect, a method of making an engineered stone product isprovided including mixing ceramic powder, glass sand, and a binder toform a mixture; compressing the mixture to form a compressed mixture,for example by vibration compression; and curing the compressed mixtureto form the engineered stone product.

DESCRIPTION Brief Description of the Drawings

The following FIGURE illustrates embodiments of the subject matterdisclosed herein. The claimed subject matter may be understood byreference to the following description taken in conjunction with theaccompanying FIGURE, in which like reference numerals identify likeelements, and in which:

The FIGURE is a schematic illustration of a method of making anengineered stone product according to an aspect of the presentdisclosure.

DETAILED DESCRIPTION

Unless otherwise defined herein, scientific and technical terms used inconnection with the present invention shall have the meanings that arecommonly understood by those of ordinary skill in the art to which thisinvention belongs, and unless otherwise indicated or the contextrequires otherwise, these definitions are applicable throughout thisdisclosure. Further, unless otherwise required by context, singularterms shall include pluralities and plural terms shall include thesingular. For example, if a term is used in this disclosure but is notspecifically defined herein, the definition from the IUPAC Compendium ofChemical Terminology, 2nd Ed (1997) can be applied, as long as thatdefinition does not conflict with any other disclosure or definitionapplied herein, or render indefinite or non-enabled any claim to whichthat definition is applied. To the extent that any definition or usageprovided by any document incorporated herein by reference conflicts withthe definition or usage provided herein, the definition or usageprovided herein controls.

Unless explicitly stated otherwise in defined circumstances, allpercentages, parts, ratios, and like amounts used herein are defined byweight.

Further, in this connection, certain features of the invention whichare, for clarity, described herein in the context of separate aspects,may also be provided in combination in a single aspect. Conversely,various features of the invention that are, for brevity, described inthe context of a single aspect, may also be provided separately or inany sub-combination.

The articles “a” and “an” may be employed in connection with variouselements and components of compositions, processes or structuresdescribed herein. This is merely for convenience and to give a generalsense of the compositions, processes or structures. Such a descriptionincludes “one or at least one” of the elements or components. Moreover,as used herein, the singular articles also include a description of aplurality of elements or components, unless it is apparent from aspecific context that the plural is excluded.

The term “about” means that amounts, sizes, formulations, parameters,and other quantities and characteristics are not and need not be exact,but may be approximate and/or larger or smaller, as desired, reflectingtolerances, conversion factors, rounding off, measurement error and thelike, and other factors known to those of skill in the art. In general,an amount, size, formulation, parameter or other quantity orcharacteristic is “about” or “approximate” whether or not expresslystated to be such. The term “about” also encompasses amounts that differdue to different equilibrium conditions for a composition resulting froma particular initial mixture. Whether or not modified by the term“about”, the claims include equivalents to the quantities. The term“about” may mean within 10% of the reported numerical value, or within5% of the reported numerical value, or within 2% of the reportednumerical value.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having,” “contains” or “containing,” or any othervariation thereof, are intended to cover a non-exclusive inclusion. Forexample, a composition, a mixture, process, method, article, orapparatus that comprises a list of elements is not necessarily limitedto only those elements but may include other elements not expresslylisted or inherent to such composition, mixture, process, method,article, or apparatus.

As used herein, the terms “sand” and “powder” are intended to refer to aparticulate solid having an average particle size of from about 10 nm toabout 5 mm, including any ranges therebetween.

Engineered stone products and methods of making the same have beendeveloped. These engineered stone products may be suitable for a numberof uses, including as countertops, sinks, flooring, and the like.Surprisingly, it has been discovered that engineered stone products canbe manufactured using ceramic powders, and that these stone products mayexhibit superior aesthetic and physical properties compared to those ofengineered stone products made using quartz sands as a major component.

In some aspects, engineered stone products are provided which includeceramic powder, glass sand, and a binder. In some aspects, methods ofmaking an engineered stone product are provided including mixing ceramicpowder, glass sand, and a binder to form a mixture; compressing themixture to form a compressed mixture; and curing the compressed mixtureto form the engineered stone product.

In some aspects, compressing the mixture to form a compressed mixtureincludes vibration compression. For example, in some aspects, thevibration compression occurs under vacuum conditions, for example at apressure of about −0.1 MPa. In some aspects, the compressed mixture iscured at a temperature of from about 85° C. to about 110° C., forexample about 85° C., about 90° C., about 95° C., about 100° C., about105° C., about 110° C., or any ranges there between.

In some aspects the ceramic powder includes an aluminium silicate. Forexample, in some aspects, the ceramic powder includes kaolinite(Al₂Si₂O₅(OH)₄), metakaolin (Al₂Si₂O₇), spinel (MgAl₂O₄), garnet(X₃Al₂Si₃O₁₂, where X is selected from Fe²⁺, Ca²⁺, Mg²⁺, and Mn²⁺) orany combinations thereof. In some aspects, the ceramic powder comprisesfrom about 0.5 wt. % to about 30 wt. % aluminum, for example from about3 wt. % to about 10 wt. % aluminum, for example about 0.5 wt. %, about 1wt. %, about 2 wt. %, about 3 wt. %, about 4 wt. %, about 5 wt. %, aboutwt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %,or any ranges there between.

In some aspects, the ceramic powder is present in the engineered stoneproduct in an amount of from about 3 wt. % to about 90 wt. %, forexample from about 30 wt. % to about 80 wt. %, for example about 3 wt.%, about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt.%, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about70 wt. %, about 75 wt. %, about 80 wt. %, about 85 wt. %, about 90 wt.%, or any ranges there between.

In some aspects, the ceramic powders have an average particle size offrom about 8 mesh to about 600 mesh, for example about 8 mesh, about 10mesh, about 50 mesh, about 100 mesh, about 150 mesh, about 200 mesh,about 250 mesh, about 300 mesh, about 350 mesh, about 400 mesh, about450 mesh, about 500 mesh, about 550 mesh, about 600 mesh, or any rangesthere between.

In some aspects, the glass sand includes a silicate. For example, insome aspects the silicate includes from about 0.5 wt. % to about 10 wt.% calcium and from about 0.5 wt. % to about 10 wt. % sodium. Forexample, in some aspects the silicate includes aluminum in an amount ofabout wt. %, about 1 wt. %, about 2 wt. %, about 3 wt. %, about 4 wt. %,about 5 wt. %, about 6 wt. %, about 7 wt. %, about 8 wt. %, about 9 wt.%, about 10 wt. %, or any ranges there between. In some aspects, thesilicate includes calcium in an amount of about 0.5 wt. %, about 1 wt.%, about 2 wt. %, about 3 wt. %, about 4 wt. %, about 5 wt. %, about 6wt. %, about 7 wt. %, about 8 wt. %, about 9 wt. %, about 10 wt. %, orany ranges there between. In some aspects, the glass sand does notinclude quartz. In some aspects, the glass sand contains less than 5 wt.% quartz, for example 4 wt. %, 3 wt. %, 2 wt. %, 1 wt. %, 0.5 wt. %, orless.

In some aspects, the glass sand has an average particle size of fromabout 5 mesh to about 600 mesh, for example from about 5 mesh to about150 mesh. For example, in some aspects the glass sand has an averageparticle size of about 5 mesh, about 10 mesh, about 50 mesh, about 100mesh, about 150 mesh, about 200 mesh, about 250 mesh, about 300 mesh,about 350 mesh, about 400 mesh, about 450 mesh, about 500 mesh, about550 mesh, about 600 mesh, or any ranges there between.

In some aspects, the glass sand is present in the engineered stoneproduct in an amount of from about 0.5 wt. % to about 30 wt. %, forexample about 0.5 wt. %, about 1 wt. %, about 1.5 wt. %, about 2 wt. %,about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25wt. %, about 30 wt. %, or any ranges there between. In some aspects, theglass sand is present in the engineered stone product an amount of fromabout 10 wt. % to about 50 wt. %, for example about 10 wt. %, about 15wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %,about 40 wt. %, about 45 wt. %, about 50 wt. %, or any ranges therebetween.

Without intending to be bound by any particular theory, it is believedthat the relative amounts of ceramic powder and glass sands present inthe engineered stone product can be adjusted to adjust the physicalperformance of the engineered stone product.

In some aspects, the binder includes a resin. For example, in someaspects, the binder includes an alkyd resin, such as an unsaturatedpolyester resin, an epoxy resin, an acrylic resin, or any combinationthereof. For example, in some aspects, the unsaturated alkyd resin isproduced using phthalic acid as a raw material, and may contain one ormore epoxy, hydroxyl, carboxyl, isocyanate, and amino groups. In someaspects, the resin may include a commercially-available resin, such asone or more ORCHEM™ resins available from Orson Chemicals. For example,in some aspects, the resin may include ORCHEM™ 707, a medium viscosity,low reactivity, non pre accelerated, non thixotropic, unsaturatedpolyester resin; ORCHEM™ 727, a UV stabilized, medium viscosity, lowreactive, non pre accelerated, non thixotropic, unsaturated polyesterresin. In some aspects, the resin may include SIMILAR® resins availablefrom Interplastic Corporation, such as SIL93BE-956, an acrylic modified(MMA) NPG-isophthalic resin with UV inhibitors. In some aspects, theresin may include Breton type polyester resins available from TurkuazPolyester. In some aspects, the resin may include Polaris™ unsaturatedpolyester resins available from Ashland. In some aspects, the binder ispresent in the engineered stone product in an amount of from about 1 wt.% to about 25 wt. %, for example from about 7 wt. % to about 15 wt. %.For example, in some aspects, the binder is present in the engineeredstone product in an amount of about 1 wt. %, about 5 wt. %, about 7 wt.%, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, orany range there between.

In some aspects, the engineered stone product further includes one ormore decorative additives. The decorative additives may include one ormore coloring pigments, reflective material, or aggregates. For example,coloring pigments may include coloring or whitening agents such astitanium dioxide (TiO₂), iron oxide pigments, phthalocyanine bluepigments, pearlescent pigments, azo pigments, mirror chips, and mixturesthereof.

In some aspects, the engineered stone product does not contain anyquartz sands. In some aspects, the engineered stone product containstrace amounts of quartz sands as a decorative additive. For example, insome aspects the engineered stone product contains less than 5 wt. %quartz sands, for example 4 wt. %, 3 wt. %, 2 wt. %, 1 wt. %, 0.5 wt. %,or less.

In some aspects, the engineered stone product has a Mohs hardness of 5or more. For example, in some aspects, the engineered stone product hasa Mohs hardness of from about 5 to about 8, for example about 5, about5.5, about 6, about 6.5, about 7, about 7.5, about 8, or any rangesthere between.

In some aspects the engineered stone product may be polished to aglossiness of at least 20°. For example, in some aspects, the engineeredstone product may be polished to a glossiness of from about 40° to about70°, for example about 40°, about 45°, about 50°, about 55°, about 60°,about 65°, about 70°, or any ranges there between. In some aspects, theengineered stone product may be honed to a glossiness of less than about10°, for example about 9°, about 8°, about 7°, about 6°, about 5°, about4°, about 3°, about 2°, about 1°, about 0°, or any ranges there between.In some aspects, the glossiness is measured by ASTM D523.

In some aspects, the engineered stone product has a water absorption ofless than 0.03% when measured by ASTM C97/C97M-18.

In some aspects, the engineered stone product has a density of fromabout 2000 kg/m³ to about 3500 kg/m³, for example about 2000 kg/m³,about 2500 kg/m³, about 3000 kg/m³, about 3500 kg/m³, or any rangesthere between.

In some aspects, the engineered stone product has an abrasion resistanceof greater than about 36 when measured by ASTM C241/C241M-15. In someaspects, the engineered stone product has an abrasion resistance of fromabout 20 to about 90, when measured by ASTM C241/C241M-15, for exampleabout 20, about 25, about 30, about 35, about 40, about 45, about 50,about 55, about 60, about 65, about 70, about 75, about 80, about 85,about 90, or any ranges there between.

In some aspects, the engineered stone product has a modulus of rupturegreater than about 30 MPa. In some aspects, the engineered stone producthas a modulus of rupture of from about 30 MPa to about 100 MPa, forexample from about 32 MPa to about 70 MPa. For example, in some aspects,the engineered stone product has a modulus of rupture of about 30 MPa,about 32 MPa, about 35 MPa, about 40 MPA, about 45 MPa, about 48 MPa,about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70 MPa,about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95 MPa,about 100 MPa, or any ranges there between, when measured by ASTMC99/C99M-15.

In some aspects, the engineered stone product has a flexural strength ofgreater than about 25 MPa. In some aspects, the engineered stone producthas a flexural strength of from about 26 MPa to about 100 MPa, forexample about 26 MPa, about 30 MPa, about 35 MPa, about 40 Mpa, about 45MPa, about 50 MPa, about 55 MPa, about 60 MPa, about 65 MPa, about 70MPa, about 75 MPa, about 80 MPa, about 85 MPa, about 90 MPa, about 95MPa, about 100 MPa, or any ranges there between, when measured by ASTMC880/C880M-15.

In some aspects, the engineered the stone product is not affected bychemical substances according to ASTM C650-04. In some aspects, theengineered stone product passes ASTM C241-15 for stain resistance.

EXAMPLES

Embodiments of the present disclosure may be better understood byreference to the following examples.

Example 1: Engineered Stone Product Composition

Four mixtures were prepared, each including 25 wt. % ceramic powder,64.5 wt. % glass sand, 10 wt. % resin, and trace amounts (0.5 wt. %) ofcoloring or whitening agents.

The compositions of the ceramic powders used in these mixtures are shownin Table 1 below:

TABLE 1 Ceramic Powder Compositions Mixture No. Sodium Aluminum SiliconOxygen 1 1.21 wt. % 13.54 wt. % 16.84 wt. % 68.41 wt. % 2 1.23 wt. %18.16 wt. % 16.29 wt. % 64.32 wt. % 3 1.19 wt. % 22.93 wt. % 15.68 wt. %60.20 wt. % 4 1.24 wt. % 28.11 wt. % 14.72 wt. % 55.93 wt. %

Each of the ceramic powders used in mixtures 1-4 had an average particlesize of between about 8 mesh and 600 mesh.

The compositions of the glass sands used in these mixtures are shown inTable 2 below:

TABLE 2 Glass Sands Compositions Mixture No. Sodium Magnesium AluminumSilicon Calcium Oxygen 1 8.86 wt. % 2.10 wt. % 1.10 wt. % 27.85 wt. %4.61 wt. % 55.24 wt. % 2 8.82 wt. % 2.15 wt. %  5.8 wt. % 27.82 wt. %4.63 wt. % 50.78 wt. % 3 8.85 wt. % 2.08 wt. % 10.5 wt. % 28.06 wt. %4.59 wt. % 45.92 wt. % 4 8.87 wt. % 2.13 wt. % 15.6 wt. % 27.74 wt. %4.60 wt. % 41.06 wt. %

Each of the glass sands used in mixtures 1-4 had an average particlesize of between about 6 mesh and 120 mesh. The particle sizedistribution of the glass sands was measured using a RO-TAP® machine,commercially available from W.S. Tyler, and is shown in Table 3 below:

TABLE 3 Particle Size Distribution of Glass Wt. % of Engineered StoneProduct Which is Glass Sand in this Particle Size Particle Size Range 6-8 mesh  5  8-16 mesh  8.5 16-30 mesh 13 30-60 mesh 15 40-70 mesh 1270-120 mesh 11

The resin used in each of mixtures 1-4 was an unsaturated alkyd resinmade using phthalic acid. The resin used in mixtures 2-4 furtherincluded up to 50% high active groups, such as cross-linking moieties,or groups which polymerize a resin and initiator. The coloring andwhitening agents included titanium dioxide (TiO₂), iron oxide,phthalocyanine blue, pearlescent pigment, and azo pigments.

Example 2: Method of Making an Engineered Stone Product

Each of the mixtures of Example 1 were used to create an engineeredstone product. The FIGURE is a schematic illustration of the method ofmaking the engineered stone product. First, the ceramic powders 101,glass sands 103, and coloring and whitening agents 105 of Example 1 weremixed in a non-gravity mixer 107, specifically a XinYin XJ-1500 mixer at3 minutes with normal machine speed to homogenize the mixture of thesedry ingredients. Next, the resin 109 was added and mixed until ahomogenous mixture was obtained, which occurred after 6 minutes ofmixing in the XinYin XJ-1500 mixer at normal machine speed.

Next, the homogenous mixture 111 was moved through a conveyor belt 113into a cloth car 115, and the cloth was placed into a cloth mold frameevenly by a cloth vehicle. Next, the cloth including the homogenousmixture was passed to a vacuum high-frequency vibration plate 117, wherethe cloth and homogenous mixture were pressed using vibrationcompression at a vacuum condition of about −0.1 MPa to form a compressedmixture.

Next, the compressed mixture was passed to a curing furnace 119, whereit was cured by heating at a temperature of between 70° C. and 150° C.for 40 minutes to form an engineered stone product. The engineered stoneproduct was then allowed to cool for 24 hours at ambient temperature,before undergoing additional finishing steps. Specifically, theengineered stone product was passed through thickening equipment toensure that the product produced had a uniform thickness. Next, theengineered stone product was polished using a 20 head pass throughpolishing machine for water grinding and polishing. Next, the quality ofthe engineered stone product was inspected, and the product was cut todesired sizes using crosscutting and bridge cutting equipment. Finally,the cut product was air-dried for 1-2 minutes at ambient temperature,packed, and stored in the warehouse.

Example 3: Physical Characterization of Engineered Stone Product

Next, the engineered stone products of Example 2 were characterized todetermine their physical properties. Specifically, the Mohs hardness,water absorption, density, abrasion resistance, modulus of rupture,flexural strength, resistance to chemical substance, and stainresistance of each engineered stone product was measured according tothe methods shown in Table 4 below:

TABLE 4 Physical Characterization of Engineered Stone Product of MixtureNo. 1 Physical Property Testing Method Value Mohs hardness EN 15771-20105 Water absorption ASTM C97/C97M-18 0.03 wt. % Density ASTM C97/C97M-182500 kg/m³ Abrasion resistance ASTM C241/C241M-15 36 Modulus of ruptureASTM C99/C99M-15 48 Flexural strength ASTM C880C880M-15 40 MPaResistance to chemical ASTM C650-04 Not substance affected Stainresistance ASTM C241-15 pass

TABLE 5 Physical Characterization of Engineered Stone Product of MixtureNo. 2 Physical Property Testing Method Value Mohs hardness EN 15771-20106 Water absorption ASTM C97/C97M-18 0.03 wt. % Density ASTM C97/C97M-182420 kg/m³ Abrasion resistance ASTM C241/C241M-15 45 Modulus of ruptureASTM C99/C99M-15 62 MPa Flexural strength ASTM C880C880M-15 60 MPaResistance to chemical ASTM C650-04 Not substance affected Stainresistance ASTM C241-15 pass

TABLE 6 Physical Characterization of Engineered Stone Product of MixtureNo. 3 Physical Property Testing Method Value Mohs hardness EN 15771-20107 Water absorption ASTM C97/C97M-18 0.02 wt. % Density ASTM C97/C97M-182450 kg/m³ Abrasion resistance ASTM C241/C241M-15 55 Modulus of ruptureASTM C99/C99M-15 68 MPa Flexural strength ASTM C880C880M-15 65 MPaResistance to chemical ASTM C650-04 Not substance affected Stainresistance ASTM C241-15 pass

TABLE 7 Physical Characterization of Engineered Stone Product of MixtureNo. 4 Physical Property Testing Method Value Mohs hardness EN 15771-20108 Water absorption ASTM C97/C97M-18 0.02 wt. % Density ASTM C97/C97M-182500 kg/m³ Abrasion resistance ASTM C241/C241M-15 70 Modulus of ruptureASTM C99/C99M-15 72 MPa Flexural strength ASTM C880C880M-15 70 MPaResistance to chemical ASTM C650-04 Not substance affected Stainresistance ASTM C241-15 pass

As can be seen from the results above, the engineered stone products ofExample 2 surprisingly exhibit improved physical properties compared toengineered stone products which contain quartz as a main component, suchas Caesarstone® products available from Caesarstone Ltd., Silestone®products available from Cosentino, S.A.U., or Cambria® productsavailable from Cambria Company LLC. Moreover, the increased amount ofaluminum included in the ceramic powders and glass sands of mixtures 2-4compared to mixture 1, combined with the high active group content ofthe resins used in mixtures 2-4 appears to have resulted in even greaterimprovements to the modulus of rupture and flexural strength of theengineered stone materials made from mixtures 2-4.

While the disclosure has been described with reference to a number ofembodiments, it will be understood by those skilled in the art that theinvention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions, or equivalent arrangements not describedherein, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

1. An engineered stone product comprising a ceramic powder of 25 wt. %to 80 wt. %, a glass sand of wt. %-65 wt. %, and a binder of 1 wt. % to25 wt. %, based on a total weight of the engineered stone product,wherein the ceramic powder comprises aluminum silicate, a content ofaluminum in the ceramic powder is 10 wt. % to 30 wt. %, and an averageparticle size of the ceramic powder is 8-600 mesh, wherein the glasssand comprises silicate, the silicate having a content of calcium of 0.5wt. % to 10 wt. % and a content of sodium of 0.5 wt. % to 9 wt. %, andan average grain size of the glass sand is 5 to 600 mesh, and whereinthe binder comprises alkyd resin, epoxy resin, acrylic resin, or acombination thereof.
 2. The engineered stone product of claim 1, whereinthe ceramic powder comprises kaolinite, metakaolin, spinel, garnet, or acombination thereof.
 3. The engineered stone product of claim 1, whereinthe aluminium silicate in the ceramic powder contains 15 wt % to 30 wt %of aluminum.
 4. The engineered stone product of claim 1, wherein thesilicate in the glass sand contains 0.5 wt. % to 5 wt. % of aluminum. 5.The engineered stone product of claim 1, wherein the sand glasscomprises sodium of 8.0 wt. % to 9.0 wt. %, silicon of 27 wt. % to 28wt. %, and calcium of 4.0 wt. % to 5.0 wt. %.
 6. The engineered stoneproduct of claim 5, wherein the sand glass further comprises 2.0 wt % to3.0 wt % of magnesium.
 7. The engineered stone product of claim 1,wherein a content of the binder is 1 wt % to 25 wt %.
 8. The engineeredstone product of claim 1, wherein the average particle size of the glasssand is 5 to 150 mesh.
 9. The engineered stone product of claim 1,comprising at least one decorative additive.
 10. The engineered stoneproduct of claim 9, wherein the decorative additive comprises one ormore selected from a colored pigment, a reflective material, and anaggregate.
 11. The engineered stone product of claim 10, wherein thecoloring pigment is selected from titanium dioxide, iron oxide pigment,phthalocyanine blue pigment, pearlescent pigment, azo pigment, mirrorpigment, and combinations thereof.
 12. The engineered stone product ofclaim 1 is capable of being polished to a gloss of at least 20°.
 13. Theengineered stone product of claim 1, having a Mohs hardness of greaterthan
 5. 14. The engineered stone product of claim 1, having a waterabsorption of less than 0.03%, measured according to ASTM C97/C97M-18.15. The engineered stone product of claim 1, having a density of from2000 kg/m³ to 3500 kg/m³.
 16. The engineered stone product of claim 1,having a wear resistance of greater than 36, measured according to ASTMC241/C241M-15.
 17. The engineered stone product of claim 1, having afracture modulus of at least 32 MPa, measured according to ASTMC99/C99M-15.
 18. The engineered stone product of claim 1, having abending strength of at least 26 MPa, measured according to ASTMC880/C880M-15.
 19. The engineered stone product of claim 1, wherein,according to ASTM C650-04, the engineered stone product is not affectedby chemical substances.
 20. A method for manufacturing the engineeredstone products according to claim 1, comprising: mixing the ceramicpowder, the glass sand, and the binder to form a mixture; compressingthe mixture to form a compressed mixture; and solidifying the compressedmixture to form the engineered stone products, and wherein compressingthe mixture to form the compressed mixture is carried out by vibrationcompression under vacuum condition of about −0.1 MPa, and the compressedmixture is solidified at ° C. to 110° C.